I'm missing my 5th gear now that I have 30.5"/235's on my '98 8V 1600.  
I had to use 4WD-L for the first time tis weekend, and whilst I understand gearing etc I don't know much about the options available for swapping diffs ect. What ratios are popular and where from?

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To help out on road you would need to reduce the axle gearing. Calmini http://www.puresuzuki.com sell sets of 5.83:1 gears. I believe that you currently have 5.12:1 so it would be a big help. I'm running the 5.83's with 33" tires and use 5th gear in the interstate at speeds of 65-75 mph.

Off road benefits would come from the axle gearing but you can gain alot more by doing a 4:1 T-case reduction. The only bad part about that is that it will not reduce you high range, so it will not help on the road.

Zig

wait for bobzooki to come back from moab to tell you just how much he likes the calmini t-case gears.  He was raving on them here and on pirate

 Personnally, I think you should cheat and go through www.ottindustries.com and use their kicker3 that mates the kick/vitara transfer case with the sammy transfer case, you get many benefits and gear selections and gearing correction in high range of 14%....the sammy case has a 1.4:1 reduction in high, the kick is 1:1 in high. Your overall low range ends up being about 4.104:1 in compound low, and is cheaper than doing the Calmini 4.24:1 gears.
Just a thought.

14% or 40% change to high ratio?  ;)I looked at this option but I don't want to run larger than 32's and figured it was too much even though it is cheaper so I'm going 5.83's and crawlers.

 Look at it this way. A sammy with that case and 5.12s can run as small as 31s with no ill effects. I think the extra reduction will help in the long run.

4.16 transfer gears will reduce your hi ratio gearing by about 12%.  Guess what the difference between stock tires and 235s are?  12%!!  You will return to stock ratio on the road, and have lower gears off road.  That is a big reason why transfer gears are so popular, they reduce low ratio gears more than hi ratio gears.  R|removethispart|@P gears reduce both by the same ratio.

Personnally, I think you should cheat and go through www.ottindustries.com and use their kicker3 that mates the kick/vitara transfer case with the sammy transfer case, you get many benefits and gear selections and gearing correction in high range of 14%....the sammy case has a 1.4:1 reduction in high, the kick is 1:1 in high. Your overall low range ends up being about 4.104:1 in compound low, and is cheaper than doing the Calmini 4.24:1 gears.
Just a thought.

WHAT WAS THE COST OF THIS SET UP    AND THEY ALSO PUT IN THE CALMINI ROCK CRAWLER T - CASE GEARS ...IS THIS A NECESSARY EXPENSE    SPEAK SLOWLY I'M MECHANICLY CHALLENGED   MATTY D.  

I think 5:83s on 30" tyres should be just about perfect. Personally I think the Vit/Track/Kick is overgeared in stock form. Having driven mine once with 25.5" tyres on it I know that it really flies along on lowered gearing (of course the speedo reads a little high too). That is of course a UK opinion, I think in the US you are used to big low revving engines and would probably find it a bit buzzy, no offence meant. I should also point out that mine is an 8V so the 20% extra power of the 16V probably means that the higher gearing suits it more.